Infrared float bar

ABSTRACT

Infrared air float bar for use in floating and drying a continuous planar web of a material in a dryer. Direct radiated or reflected infrared electromagnetic energy from an infrared light source in a removable channel assembly accelerates drying, or evaporation of solvents, or curing of web material passing in proximity to the bar, either by infrared electromagnetic energy, or in combination with convention airflow. The infrared source is cooled by pressurized air passing through an interior portion of the removable air bar channel assembly, and the air is further conducted into fluid contact with the web in an air gap between the emitter and web to promote convective heat transfer and to contribute to the air pressure field supporting web flotation. The removable channel assembly is configured for replacement of the infrared emitter and to allow the setting of the pressurized cooling air flow to the optimum level.

This application claims priority of U.S. Provisional Application Ser.No. 61/184,353 filed Jun. 5, 2009, the disclosure of which isincorporated herein by reference.

BACKGROUND

Embodiments disclosed herein relate to an air float bar for use inpositioning, drying or curing a continuous generally planar flexiblematerial such as a web, printed web, newsprint, film material, orplastic sheet. More particularly, they pertain to an air float bar whosepressure pad area includes an infrared light source, such as an infraredbulb, a reflector surface and a lens to enhance accelerated infraredheating of web material to cause solvent evaporation, drying and/orcuring. Electromagnetic infrared heat energy in combination with jets ofair impinging upon the web surface provide for concentrated heating ofthe web material, thereby providing subsequent rapid evaporation, dryingand/or curing from the surface of the material.

U.S. Pat. No. 5,035,066 (Wimberger) teaches the integration of aninfrared emitter into a Coanda-type flotation air bar. Cooling air isbrought through a channel assembly that encloses the emitter. A quartzlens is used to enclose the emitter while allowing transmission ofelectromagnetic energy in the range of infrared wavelengths to pass fromthe channel assembly enclosure to the web. In one embodiment, saidcooling air, after passing around the emitter inside said channelassembly, is discharged through holes in a quartz lens of said emitterchannel assembly. Although this arrangement provides some recovery ofheat by discharging said cooling air to the web surface after flowingaround said emitter, the flow path is not optimized for both cooling ofthe emitter and recovering of heat to the air which is subsequentlyimpinged on the web. The prior art arrangement with passage of airthrough holes in the quartz lens does not provide optimum fluid contactto effectively cool the emitter and lens as is desired in order tomaintain longevity of these components against thermal degradation orcontamination. Nor does it maximize the recovery of heat from theemitter, lens and reflector. It is further desirable to keep the emitterand lens free from contamination by aggressive solvent vapors, liquidssuch as inks and/or coating materials, and other contaminants such aspaper dust or chards of material from broken webs. Cooling andprevention of contamination of the reflector is also desirable for thesame reasons as discussed for the lens. If such contamination occurs,the infrared energy is absorbed by the quartz material of the emitterand quartz lens instead of being transmitted through said quartz to theweb surface, which results in loss of drying and heat transferefficiency, and also promotes thermal degradation as the designtemperatures of the emitter and lens materials may easily be exceeded.Similarly, contamination will reduce the reflectivity of the reflectorresulting in loss of drying and heat transfer efficiency and materialthermal degradation.

As is known to those skilled in the art of infrared dryers, it isdesired to prevent possible ignition of combustible materials, such apaper web, should said combustible materials come into contact with hotsurfaces. It is further desired to have a quick acting means ofinterrupting the heat flux from the infrared emitter from reaching theweb to prevent ignition of a stationary or broken web. A means ofblocking the infrared heat flux is taught in U.S. Pat. Nos. 6,049,995and 6,195,909 (Rogne et al.) but requires detection and an activemechanical means to assure that the web is not exposed to temperaturesexceeding the ignition temperature of materials being processed. As isknown to those skilled in the art, it is often desirable to usefast-cooling tungsten or carbon filament emitters as are available fromHeraeus Noblelight of Hanau, Germany. These fast-cooling elementsminimize the time necessary to bring the infrared heat flux andassociated surface temperatures low enough avoid ignition of saidcombustible materials should the web stop or break during an upset tothe drying process. Even with such quick cooling emitters, it isdesirable to keep the exposed surfaces of the air float bar as cool aspossible at all times to prevent possible ignition of said combustiblematerials, even when web stoppage or a web breakage upset may goundetected.

It is also known to those skilled in the art of drying materials bymeans of infrared energy that the amount of heat effectively absorbed bythe material is dependant on a number of key factors, including thetemperature of the emitter, the geometry defining the infrared lightpaths to the materials, and the absorption characteristic of thematerials to be dried. It is desired to select an emitter type such thatits temperature will emit maximum electromagnetic energy flux in therange of wavelengths that correspond with the wavelengths of maximumabsorption in the material to be dried. In the case of a coated web thematerials typically include the base web substrate, and a coatingcomprised of solids, and a solvent such as water or an organic solvent,said solvent to be dried. Each of these materials exhibits an infraredabsorption characteristic as a function of infrared wavelength, orspectra, which is to be considered in the selection of the type ofemitter to be used.

In some cases, such as printing, the coating or ink is not applied tothe substrate uniformly in all areas. It such cases it is desirable tomaximize the infrared energy flux to the areas having coating or inkwhile minimizing the energy flow to uncoated (unprinted) areas. Thelocations of the coated and uncoated areas are variable according to theproduct to be dried. One prior art method used to effect the directionof drying energy to areas requiring drying while limiting energy toareas not requiring drying prescribes the selection of the emitter suchthat it will provide high infrared heat flux at a range of wavelengthsthat match high absorption wavelengths for the solvent, while minimizingthe emission of infrared energy at wavelengths where absorption in thedry solids and the substrate is low. Another prior art method arranges aplurality of emitter lamps in an array wherein the emitter lamps may beactivated (energized) or deactivated (de-energized) to emit infraredenergy approximately matching the physical location of the areas to bedried. In the drying of moving continuous webs having widely variablepatterns of printed and unprinted areas, this method of activating anddeactivating a fixed array is only practically capable of directingdrying energy on a spatially coarse scale. The infrared energy can beapplied more or less in lanes along the length of the web to be dried,which does not address the need to limit drying heat to the unprintedareas that lie between printed areas along the direction of web travel.

SUMMARY

The embodiments disclosed herein offer an improvement over the prior artby guiding the cooling air in a path which maximizes the cooling of anemitter, an optional lens and reflector surfaces while providingadditional convective heat transfer to the web and additional webflotation support, while shielding surfaces of said emitter, lens andreflector from contaminants described earlier. Exposed surfaces of theair float bar are kept at the lowest possible temperature to minimizethe risk of ignition of the web or other materials being processedwithout the use of mechanical shutters or shields.

The general purpose of the embodiments disclosed is to provide aninfrared air float bar for use in the heating and/or drying of webs,such as for use in a web dryer. The design of the air float bar elementmay be selected from several types as are known to those skilled in theart. Example designs of float bars are taught by Frost, U.S. Pat. No.3,549,070, and Rocheleau, U.S. Publ. No. 2005/223593, but it is to beunderstood that the flotation bar element of the present invention isnot limited to these particular examples. Included are one or moreinfrared emitters integrated into the air float bar for the generationand transmission of infrared electromagnetic radiation to the web, andadditional heat is transferred to the web by convection air having beenheated convectively in the process of cooling the emitter and associatedreflector and lens elements.

It can be appreciated by those skilled in the art that air flotationbars provide convective heat and/or mass transfer owing to the action ofthe air jets on the web as it is floatingly supported in an array of oneor more air bars. The air supplied to said jets may be heated by anindependent heat source, such as an electric resistance coil, hot oil orsteam coil, or a burner located in the ducting supplying the air to oneor more air bars in the dryer. In the case of an infrared air flotationbar, cooling air is heated by the infrared emitter, and thus heatedbecomes a medium for enhanced convection heat transfer and mass transferto the web within the dryer. Said cooling air, now heated, may bebrought in to convective contact with the web to enhance heat transfer.In embodiments disclosed herein, the cooling air path is arranged andthe air flow mass adjusted to provide sufficient cooling to protectelement surfaces as previously mentioned and to avoid potential ignitionof web materials while maximizing the temperature and therefore theamount of useable energy taken up by the cooling air for use in heatingand drying the web. Furthermore, the heated cooling air and flotationair jets are discharged and mingled in the area directly between the weband air bar and transfer heat convectively while floatingly supportingthe web.

After convectively contacting the web, the combined air may be drawnback to the air supply of the dryer and a portion re-circulated again tosupply the one or more air bars. Energy consumption to run the dryer isminimized when the amount of air re-circulated is maximized. The exhaustventilation rate, that is the balance of air not re-circulated, may beset by those skilled in the art of drying to maintain a desired wet bulbtemperature within the dryer such that the drying rate is maximized.Typically in the case of drying non-flammable solvents such as water,the re-circulation rate may be maximized to a high level, often in therange of 50 to 95% of the total convection drying air flow supplied tothe air bars. In the case of flammable solvents, the ventilation rate ismost often set to meet the ventilation safety requirements requiring thedryer to operate well below, typically 25% of, the lower explosive limitconcentration of the solvent or solvents being dried. In a preferredembodiment, the supply air to one or more infrared flotation air barsnozzles is heated only by the infrared emitter elements, that is noother independent heater is required to heat the supply air, this savingspace and component costs for air handling equipment. In a mostpreferred embodiment, by maximizing the re-circulated air within thedryer in a range from 70 to 95%, the convection air supplied to theinfrared flotation nozzles may be heated to a desired temperature,preferably in the range of 150 to 300° F. for drying of water-basedcoatings and inks.

In a further embodiment, the flow and temperature of the air supplied tothe infrared air bar is regulated to obtain a desired convection heatflux to complement the infrared heat flux to the web being dried. Thisprovides a unique means to preferentially direct the heating of the webwhile drying both wet and dry areas on the same web, as in the case ofprinting. While drying under conditions of constant infrared emittertemperature and constant convection air velocity and temperature, thewet areas of the web are substantially cooled by the evaporative energyneeded to vaporize the solvent, such as water. As is well known to thoseskilled in drying, the wet areas tend to approach the wet bulbtemperature and remain at approximately that temperature during theconstant rate drying period, until sufficient liquid is evaporated andthe evaporation rate is limited by the falling rate drying period. Uponentering the falling rate drying period, the web temperature then climbsas the evaporative cooling diminishes. In the case of printing, someareas of the web are heavily covered with ink while some areas may havelittle or no coverage. These low coverage areas are relatively dry andoften enter the falling rate drying period almost immediately uponentering the dryer. Thus the web temperature in these areas increasessignificantly in contrast to relatively wet areas, and often reaches atemperature at the exit of the dryer which exceeds the desired level.This may result in damage to the web product as well as wasting energyin overheating these areas.

In embodiments disclosed herein, the high convection heat transfercharacteristic of the infrared flotation bars is applied in combinationwith infrared radiation mode such that the web temperature differencebetween relatively wet and dry areas at the exit of the dryer may bereduced. This is accomplished by the combined action of the two heattransfer modes: convection and radiation. Those skilled in the art ofheat transfer recognize that the heat flux via the two modes actsimultaneously and the contribution from each mode may be additive orwork opposite to another. That is, while infrared energy is heating anobject, it may at the same time be losing heat via convection. It is anobject of the embodiments disclosed herein to provide a balance of thetwo aforementioned heat flux modes such that the overheating ofrelatively dry areas, such, as non-printed areas is avoided or mitigatedwithout the limitations of prior art already described.

Typically when the web first enters the dryer, it is cooler than the airtemperature and thus effectively heated additively by both radiation andconvection modes. As the web increases in temperature, especially inrelatively dry (low coverage) areas, the infrared energy continues toheat the web, but as the web temperature eventually exceeds theregulated air temperature in the dry areas, the convection heat transfernow acts opposite to the infrared radiation and the air tends to keepthose areas of the web relatively cooler. Meanwhile, the wetter areas(higher coverage) will remain at a lower temperature (below theregulated air temperature) owing to the evaporative cooling effectpreviously described. Consequently, the drying rate is enhanced by bothheat transfer modes in the wetter areas from heating by both radiationand convection. By regulation of the air temperature to a level justabove the wet bulb temperature in the dryer, the combined infrared andconvection drying characteristics of the present invention a selectivedrying condition is enabled wherein fast drying is promoted in highcoverage areas while mitigating the tendency to overheat the web in lowcoverage areas.

In prior art, the only requirement of the cooling air has been to limitthe temperature of the emitter and associated elements such as thereflector and lens. As mentioned above it is an object of theembodiments disclosed herein to regulate the temperature of the airsupplied to the infrared air bar to meet a web temperature heatingbalance in wet versus dry areas. As the cooling air temperature is nowdesired to be a regulated variable, this places additional designrequirements on the embodiment of the cooling provisions for emitter andassociated elements. In the embodiments described herein, the coolingair flow volume and path take into consideration this variation in airtemperature. Looking more specifically to the design of the infrared airbar, infrared electromagnetic energy waves pass from an emitter filamentby transmission in a straightforward direct manner to impinge on atraversing web. Said infrared waves pass transmissively through theemitter bulb casing used to hold and protect the filament, and through aplanar lens. The bulb casing and lens materials are typically of quartzmaterial having transmissive properties in the wavelength range ofinfrared electromagnetic energy. Infrared electromagnetic waves are alsoreflected in an indirect manner from the emitter to a reflector surfacethat reflects the waves, which then further pass through the planar lensto impinge upon the traversing web. As is known to those skilled in theart of infrared energy, a portion of the electromagnetic energy thatenters a transmissive material or impinges on a reflective surface isabsorbed. This absorbed energy raises the temperature of thetransmissive or reflective material and may lead to degradation of thetransmissive or reflective property, substantially reducing the energyreaching the web, and also result in early failure of the emitter andlens material. This energy is useful in heating and drying the web whenrecovered in an air stream, which is then brought into fluid contactwith the web. Energy recovery and cooling effectiveness are maximizedwhen carried out in a manner that provides uniform fluid contact with acontrolled quantity of air. Optimization of the present embodiments hasshown that this can be accomplished by passing from 5 to 40%, preferablyfrom 7 to 15%, of the total air supply delivered under pressure to thefloater bar through an air distribution means into uniform fluid contactwith the emitter bulb, and further uniformly guide the flow path influid contact over the surface of the reflector, and further intouniform fluid contact with both faces of the planar lens. Mostpreferably, this flow of cooling air is in the range of 7 to 15% of thetotal supply air to the floater bar. In addition, the uniform fluidcontact of cooling air with the emitter bulb, reflector and lenssurfaces prevent contamination by solvents and other materials mentionedpreviously.

In certain embodiments, there is disclosed a channel assembly adapted tobe inserted or retrofitted into an air bar, wherein the channel assemblyhas a compartment defined by a bottom having at least one aperture and apair of opposing sides, the compartment comprising an infrared lightsource, a reflector of infrared light, and a lens transmissive toinfrared light. The aperture allows for the flow of cooling fluid aboutthe infrared light source, reflector and lens in the compartment. Theremovable channel assembly is configured for replacement of the infraredemitter and to allow the setting of the pressurized cooling air flow tothe optimum level. Thus, the channel can be removed and the infraredlight source replaced or repaired, and the channel then reinserted intothe air bar, or the channel can be removed and a new channel can beinserted into the air bar.

In a preferred embodiment, the setting of the flow of cooling airthrough the at least one aperture is adjustable. The flow through the atleast one aperture is set by an adjustment of a moveable element inrelation to a fixed element, so as to allow an increase or a decrease inthe aperture flow area of the combined moveable and stationary elements.This setting is made by adjusting the position of said movable elementto obtain sufficient cooling of the emitter and associated elements withthe maximum regulation setting for the supply air temperature in orderto avoid thermal degradation of the materials selected. In addition thecooling air flow is set to maintain the surface temperatures of the lensand air bar and other surfaces that may contact the web, should the webbreak or otherwise lose tension, to a temperature below the ignitiontemperature of the web material, preferably <400° F. The practical rangefor the cooling air flow setting has been found to be from 5 to 40%,most preferably 7 to 15%, of the total supply air delivered to theinfrared air bar.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an IR float bar in accordance withcertain embodiments;

FIG. 2 is a cross-sectional view of the IR float bar of FIG. 1 showinginfrared energy waves;

FIG. 3 is a cross-sectional view of the IR float bar of FIG. 1 showingairflow patterns;

FIG. 4 is a cross-sectional view of a single-side flotation IR air foilin accordance with certain embodiments;

FIG. 5 is a cross-sectional view of a single-side flotation IR step foilin accordance with certain embodiments;

FIGS. 6A-6D are schematic illustrations of various IR bar configurationsin accordance with certain embodiments;

FIG. 7 is a cross-sectional view of a Coanda air float bar having two IRlight sources in accordance with certain embodiments;

FIG. 8A is a top view of an air bar showing an air flow adjustmentmechanism in accordance with certain embodiments;

FIG. 8B is a side view of an air bar showing an air flow adjustmentmechanism in accordance with certain embodiments;

FIG. 8C is a bottom view of an air bar showing an air flow adjustmentmechanism in accordance with certain embodiments;

FIG. 8D is an end cross-sectional view of an air bar showing an air flowadjustment mechanism in accordance with certain embodiments;

FIG. 9A is a top view of an air bar showing an air flow adjustmentmechanism in accordance with certain embodiments;

FIG. 9B is an end cross-sectional view of an air bar showing an air flowadjustment mechanism in accordance with certain embodiments;

FIG. 10 is a schematic diagram of a dryer incorporating a plurality ofIR float bars in conjunction with supply air, re-circulating air andexhaust air features in accordance with certain embodiments;

FIG. 11 is a schematic diagram of the dryer of FIG. 10A depicting supplyair, re-circulating air and exhaust air flow paths;

FIG. 12 is a schematic diagram of a dryer incorporating a plurality ofIR float bars in conjunction with supply air, re-circulating air andexhaust air features in accordance with certain embodiments; and

FIG. 13 is a schematic diagram of a dryer incorporating a plurality ofIR float bars with controls in conjunction with supply air,re-circulating air and exhaust air features in accordance with certainembodiments.

DETAILED DESCRIPTION

In general, the float bars disclosed herein have one or more primary airjets which discharge from slots. The primary jets create a pressurefield to floatingly support a web. The air supplied to the primary jetsmay be optionally heated to enhance heat and/or mass transfer for dryingof the web. Air for cooling the emitter, reflector and lens elementscontained in a removable channel may be taken from the same supplyplenum as the primary flotation air, or alternately ducted from aseparate air source to the channel assembly. After contacting theemitter, reflector and optional planar lens, the cooling air isdischarged through one or more secondary jets which sweep the face ofthe planar lens and prevent contact of the web and solvent materialsfrom the lens.

FIGS. 1 and 2 show a preferred embodiment wherein the floater barelement 10 is of the Coanda type having two primary flotation jets; afirst primary flotation slot 12A and a second primary flotation slot12B. Two secondary air slots 14A and 14B, that are preferably 5 to 40%of the primary slots 12A, 12B, most preferably 15 to 30% are alsoprovided as shown. Supply air enters the supply plenum 15 of the air bar10 via a supply air feed inlet 16 (e.g., a plurality of oval shapedapertures) located at the bottom 18 of the air bar 10 and is distributedalong the length of the air bar to obtain suitable distribution to theflotation jets as is known in the art. An infrared element is configuredas a channel assembly comprised of a supporting channel 20 whichcontains a reflector 21 in fluid communication with the supply airplenum 15, or a separate cooling air source as mentioned earlier, bymeans of one or more apertures 22 which penetrate the base channel andare in substantial alignment with comparable apertures 23 in thereflector 21 at the point of tangent contact with the base channel 20.The total area of the apertures is preferably equivalent in flow area to20 to 100% of the area of the primary flotation slots 12A, 12B, that is,slot length×slot width×number of slots. The active area of the aperturesmay be adjusted by aligning the array of apertures in the reflector 21with a comparable array of apertures in the base channel 20, rangingfrom full alignment to complete closure, thus acting as an adjustabledamper for setting of the cooling air flow. Suitable mechanical means ofsliding the reflector with respect to the base channel to achieve thedesired alignment can easily be accomplished by those skilled in theart.

FIGS. 8A-8D show preferred embodiments for the sliding and stationaryelements in the channel assembly to enable the adjustment of theinfrared emitter cooling air flow. FIGS. 8A and 8B show a slidingadjustment element 27 with circular apertures 22 a that can be alignedwith corresponding preferably larger apertures 22 in the removablechannel 20. Corresponding oversized apertures are located in reflectorelement 21 such that these apertures coincide with the apertures 22 inremovable channel 20. Sliding adjustment element 27 has adjustment slots27 a to allow the moveable element 27 to slide in position relative toreflector 21 and removable channel 20 such that the aperture 22 openarea is reduced from the fully concentric alignment position. Once theappropriate position of the adjustment element is found, the adjustmentelement can be fixed in place such as by tightening bolts or the like inthe slot 27 a. FIGS. 9A and 9B show a more preferred embodiment whereinapertures 22 a in the sliding adjustment element 27 and the apertures 22in removable channel 20 are diamond shaped, thus allowing a fineradjustment of flow when moving the sliding adjustment element whenreducing the aperture 22 flow area. Apertures 23 in the reflector 21 areoblong.

The removable channel 20 includes a bottom member 40 that is supportedon distribution member 24, and opposite side members 41A, 41B that eachterminate in inwardly facing terminal ends 11A, 11B. The outer surfaceof the chamber 20 transitioning between the sides 41A, 41B and therespective terminal ends 11A, 11B are curved so as to define, with thecorresponding terminal ends of the sides 7A, 7B of the air bar 10,Coanda slots, which are the primary flotation slots 12A, 12B. Theremovable channel 20 can be slidingly removed from the air bar 10, alongwith its contents, and either be replaced by another channel, or by thesame channel after maintenance or replacement of the lens and/or bulbcontained therein.

An initial air distribution member 19, such as a perforated plate, canbe provided in the air bar 10 to enhance uniform supply airdistribution. An open area of about 13% in such a member has been foundto be suitable. A secondary air distribution member 24, such as plateperforated with slots or holes, can be positioned downstream of theinitial air distribution member 19 as shown, and also can serve tosupport the removable channel 20.

The channel 20 contains an infrared light source 30, such as an IRemitter bulb commercially available from Heraeus Noblelight GmbH. A lens32, preferably a planar quartz lens, can be positioned above the IRlight source 30 as shown. The lens encloses the emitter while allowingtransmission of electromagnetic energy in the range of infraredwavelengths to pass through and reach the web 50 floating above the bar10 (FIG. 2). Electromagnetic energy emitted from the IR light source 30passes through the lens 32 and directly radiates onto the web 50. Areflector 21 is also contained in the channel 20, and is preferablyparabolic and made of a suitable reflective material such as stainlesssteel or aluminum. Preferably the reflector 21 extends from the lensdownwardly below the IR light source, thereby surrounding the IR lightsource except in the area occupied by the lens, so that light emittedfrom the light source radiates either directly through the lens or isreflected by the reflector towards the lens, and is then ultimatelyradiated onto the web 50, as shown diagrammatically in FIG. 2.

The secondary slots 14A, 14B are defined by the clearance (e.g., 0.0010″to 0.003″) provided between the lens 32 and the inwardly facing terminalends 11A, 11B of the chamber 20. As illustrated diagrammatically in FIG.3, supply air fed into the air bar at inlet 16 flows through theperforated initial air distribution member 19, through perforatedsecondary air distribution member 24, out through primary flotationslots 12A, 12B where a pressure pad or field is created to floatinglysupport the web 50. Supply air also passes through the cooling air entryjets in the member 24, the bottom 40 of the channel 20, and thereflector 21, and flows in the area defined by the reflector 21 and thelens 32. That air thus cools the emitter 30, the reflector and the lens.The resulting heated air then flows out of the interior of the channel20 through one of the secondary slots 14A, 14B, and sweeps the face ofthe lens 32, thereby preventing contact of the web and solvent materialsand other debris or contaminants with the lens 32. Those skilled in theart will appreciate that the fluid for cooling the emitter, reflectorand lens elements may be ducted from a separate air source to thechannel assembly.

In certain embodiments, the lens 32 can be omitted, and the airdischarged from the channel assembly can be used as a virtual lens,effectively shielding the emitter 30 from the web and potentiallyhazardous debris or contaminants.

FIG. 4 illustrates an embodiment wherein the float bar is a single-sideflotation air foil 10′. In this embodiment, a single primary flotationjet 12′ is provided to discharge supply air to float the web 50, and asingle secondary jet 14′ is provided to discharge cooling air from theremovable channel assembly 20′. The air foil 10′ is defined in part by aheader, which in the embodiment shown, is generally rectangular incross-section except for its top portion. Opposite sides 7A′, 7B′ of theheader terminate in respective top flange portions 8A′, 8B′. Top flangeportion 8A′ is angled, preferably at about 65° relative to vertical, andterminates in a bent portion 13′. Top flange portion 8B′ extends towardsopposite side 7A′ in a substantially horizontal fashion. The headerdefines an interior space 15′ that serves as a plenum for the gas thatis received via the one or more holes (not shown) at the base of the airfoil 10′ that are in gas-receiving communication with a gas supply (notshown). The header is positioned on suitable ducting by aligning thealigners 3 at each end plate of the header and is sealed by retainergasket 4. A diffuser plate having a plurality of spaced holes can bepositioned in the header to help distribute the supply of gas evenly asit flows towards the slots.

The flange portion 8A′ and bent portion 13′ of the header, together withthe flat portion 23 of the member 25, defines the primary slot of theair foil. Air flows out the primary slot 12′, and continues in thedirection of web travel towards the wing 35 of the air foil, which wing35 terminates in a flange 34 extending downwardly at a right angle about0.5 inches. The air then travels along the top face of the wing in thedirection of web travel to support the web. As in the embodiment of FIG.1, an optionally removable channel assembly 20 is provided, and containsa reflector 21, a lens 32, and an IR light source 30. Air enters thechannel assembly 20 through one or more apertures 22′ in the member 25,each aligned with a respective aperture 23′ in the bottom 40′ of thechannel 20, and cools the reflector 21, the light source 30, and thelens 32. The cooling air (now heated) is discharged from the channel 20via the clearance between the lens 32 and the flat port 23.

FIG. 5 illustrates an embodiment wherein the float bar is a single-sideflotation step foil 10″, such as that disclosed in U.S. Pat. No.7,530,179, the disclosure of which is hereby incorporated by reference.Like the air foil 10′ of FIG. 4, an optionally removable channelassembly 20 can be provided that contains the reflector 21, IR lightsource 30 and lens 32. Differences between the embodiment of FIG. 5 andthat of FIG. 4 include in the FIG. 5 embodiment the provision of asecond secondary slot 14B′, spaced from and stepped down from theprimary slot 12A, is to aid in floating the web 50. Air discharged fromthe secondary discharge slot 14B travels parallel to the web. Airdischarged from the primary discharge slot 12A is gathered into the airstream of the secondary discharge slot 14B′ in a direction parallel tothe web transport direction. Between the primary discharge slot and thesecondary discharge slot is a generally flat web support surface,including the face of the lens 32. Downstream of the secondary dischargeslot, in the direction of web travel, is a second web support surfacethat comprises a wing portion that slopes downwardly as it extends awayfrom the secondary discharge slot 14B′. This second web support surfaceoptionally can include a second lens 332 that forms part of an optionalsecond channel assembly 200 comprising a reflector 221, an IR lightsource 300, and the lens 332. the side 7B of the stepfoil can includeone or more apertures 60 to allow supply air (or air from anothersource) to enter the channel assembly and cool the components therein asabove.

FIG. 7 illustrates a further embodiment, in a Coanda nozzle having twoCoanda discharge slots 12A″, 12B″. In the embodiment shown, an IR lightsource 30″ is positioned upstream, in the direction of web travel, ofthe first Coanda discharge slot 12A. Bent member 8A″ that defined inpart the Coanda discharge slot 12A″ includes one or more apertures thatallow air to pass through and flow about the IR light source 30″ to coolthe same. A lens 32″ can be positioned above the light source 30″ thatis transmissive to electromagnetic energy, and if provided, the lens isalso cooled by the flow of air that cools the light source 30″.Alternatively, the cooling air can function as a virtual lens, keepingthe light source 30″ cool and free of debris and contaminants. A secondIR light source 30A″ can be positioned downstream, in the direct of webtravel, of the second Coanda slot 12B″, arranged in a manner similar tothe upstream assembly. The downstream assembly is shown without a lens,although one could be used as in the upstream assembly.

FIGS. 6A-6D illustrate suitable arrangements of pluralities of infraredbars with respect to a traversing web 270. It is noted that the air barsshown are illustrative only; any of the air bar embodiments disclosedherein (e.g., Coanda, air foil, step foil, etc. can be used). Otherarrangements are also possible.

FIG. 6A illustrates a plurality of infrared air bars 272 a-272 npositioned below a traversing web 270.

FIG. 6B illustrates a plurality of infrared air bars 274 a-274 npositioned above a traversing web 270.

FIG. 6C illustrates a plurality of infrared air bars 276 a-276 n and aplurality of infrared air bars 278 a-278 n in an opposing verticallyaligned arrangement about a traversing web 270 for rapid drying of thetraversing web 270.

FIG. 6D illustrates a plurality of infrared air bars 280 a-280 n and aplurality of infrared air bars 282 a-282 n arranged in alternatingopposing vertical arrangement about a traversing web 270 creating asinusoidal shape for the traversing web 270.

FIGS. 10-13 illustrate preferred embodiments of infrared air float barsarranged in a dryer enclosure 301 having a web 270 entering saidenclosure through web slot 305 a and exiting through exit slot 305 b,said web floatingly traverses through a combined convection and infraredradiation heating zone created by infrared air bars which directinfrared energy to the web and handle distribution of heated supply airjets to impinge on the web. The enclosure 301 contains the spent heatedair after fluid contact with the web such that collection of at least aportion of the spent air may be recovered for re-circulation to the airbars. At least a portion of the spent air is exhausted from theenclosure as described in the embodiments herein.

FIG. 10 illustrates a dryer embodiment 300 a comprised of a plurality ofinfrared air bars 280 a-280 n mounted to and in fluid communication withan air supply distribution header 310 a, and a plurality of infrared airbars 282 a-282 n mounted to and in fluid communication with an airsupply distribution header 310 b. Fluid communication between theplurality of infrared air bars 280 a-280 n and 282 a-282 n to eachrespective header 310 a and 310 b is made through feed openings 315a-315 n. The air feed openings 315 a-315 n are connected and sealed toair bar feed inlet 16 (FIG. 1) by means of separation joints 316 a-316 nwhich allow easy disconnection and removal of the infrared air bars fromthe dryer. The joints 316 a-316 n may be sealed with gasket material,compression seats, or other similar means as are known to those skilledin the art of flotation dryer design. FIG. 11 illustrates the air flowpaths created by the air flow elements within the enclosure 301 of dryer300 a of FIG. 10 herein described. A zone supply fan 320 collects heatedair from inside the enclosure 301 and discharges said air under pressureinto a plenum 322 having an optional heat source 325. This heat sourcemay be a fuel burner, a heat exchange coil from a heating media such ahot water, steam, or thermal oil, or preferably an electric element ductheater. After passing through optional heater 325, the heated air isdirected to air distribution headers 310 a and 310 b via ducts 326 a and326 b, respectively. Optional heater 325, if provided, may be controlledby an air temperature control loop 340. The heated air is thendistributed to infrared air bars through feed openings 315 a-315 nwherein it is used to cool the internal elements of the infrared airbars. The air flow paths and cooling function within each infrared airbar have been described previously. Electrical power fed to the emittersis regulated by an operator through a user interface in communicationwith an SCR according to the web drying load in order to achieve asatisfactorily dried product. Once discharged from the air bar, the aircomes into fluid contact with the web to convectively exchange heat andmass with the web 270. Following this exchange step, at least a portionof this “spent” air is drawn back to the inlet of supply fan 320. Anamount of room air is drawn into enclosure 301 through web slots 305 aand 305 b. An exhaust flow balancing this room air and any evaporatedsolvents from the web must be continually ventilated out of theenclosure. To this purpose, a separate exhaust fan 331 draws at least aportion of said spent air through exhaust duct 332 and flow controldamper 336 and discharges it to atmosphere. Alternatively, the exhaustflow rate could be controlled by a variable speed motor and driveconnected to exhaust fan 331 instead of control damper 336. The separateexhaust fan 331 of dryer embodiment 300 a is necessary for safelyhandling volatile flammable solvent materials and/or in the case adirect fired fuel burner is used for optional heater 325. Exhaust flowsafety ventilation volume and treatment equipment (not shown) for airpolluting materials in said exhaust may be required based onrequirements set forth by parties having such jurisdiction as will beunderstood by those familiar with such regulations in their locale.

FIG. 12 illustrates a preferred dryer embodiment 300 b for drying anon-flammable solvent, such as water, wherein supplemental heat beyondthat provided by the infrared air bars is not needed to meet the thermalload required by the web. In some cases, where web drying heat loadrequirements are less than would be output by fully populating all airbar positions in distribution headers 310 a and 310 b, one or morepositions for mounting air bars may be occupied by an air bar without anactive infrared emitter, thus reducing the connected power load of thedryer. In the illustration of FIG. 12, the supply air header 310 a isnot fully populated with infrared air bars, but includes twonon-infrared air bars 281 a and 281 b. Note these non-infrared air barsmay be of a number of types which are familiar to those skilled in theart of air bar design. The non-infrared air bars are preferentiallylocated near the web exit end of the dryer, and in the case of asingle-side coating on the web, located on the uncoated side. Electricalpower fed to the emitters is regulated by an operator through a userinterface in communication with an SCR according to the web drying loadin order to achieve a satisfactorily dried product. The supply airtemperature is regulated by control loop 340 to maintain a set point bymodulating the amount of exhaust through exhaust duct 330 by means ofdamper 335.

FIG. 13 illustrates a preferred embodiment for a single-side coated orprinted web wherein the ink or coating is on the bottom side of the web.Electrical power fed to emitters 282 a-282 n is regulated by an operatorthrough a user interface in communication with an SCR 342 according tothe web drying load in order to achieve a satisfactorily dried product.The air temperature is controlled through control loop 340 a whichregulates the power setting to SCR 341 which in turn modulates the powerto the emitters in infrared air bars 280 a-280 n facing the uncoatedside of the web.

The operation of the air bars will be illustrated with reference to theembodiment shown in FIG. 3. A plurality of infrared electromagneticenergy rays increase drying capacity because the infrared source islocated at the point of highest heat transfer, e.g., between thedischarge slots and radiate from the infrared source 32 either directlyor indirectly through the lens 32. The infrared drying energy istransmitted for heating a traversing web being processed in a dryer. Aportion of the infrared rays reflect off the parabolic reflector 21 andthrough the lens 32 to impart infrared drying energy upon and heatingthe web. The wave length of the infrared electromagnetic rays emittedfrom the infrared source 32 can be short wave with a wave length of 0.78to 1.2 microns, medium wave length with a wave length of 1.2 to 4.0microns or long wave length of 4.0 to at least 10 or more microns. Incertain embodiments, the infrared source 32 is positioned at a point ofmaximum energy transfer.

Pressurized air to float the web enters the infrared air bar through theplurality of oval shaped air inlets 16 to float the web. From the airinlets, the pressurized air proceeds as indicated by dashed arrow lines(FIG. 3) through the holes of the initial air distribution member 19,through the holes of the secondary air distribution member 24, throughthe Coanda slots 12A and 12B, along the Coanda curves defined by theside members 41A, 41B of the channel assembly 20, and then inwardlyalong the upper surface of the lens 32 and upwardly, thus providingfloat lift for the web 50 and also carrying away solvent vapors in theweb. Air also flows into the channel 20 and around the elements disposedtherein to cool the same, and then ultimately leaks out through theclearance between the lens 32 and the side members 41A,41B and sweepsover the outer face of the lens 32.

Direct and indirect infrared energy rays impinge on the web 50 and heatthe web as it passes over the pressure pad created by the Coanda slots,thus drying and evaporating solvents from the web. This, in combinationwith impinging flow of air, maximizes the heat transfer in the area ofthe pressure pad.

Output of the infrared source 30 can be variably controlled, such as byan SCR so that the amount of energy output transmitted from the infraredsource includes a range from full power to no power, and any variablerange therebetween.

Embodiments disclosed herein provide an air float bar with at least oneprimary air jet for flotation flow and heat transfer to the web and atleast one integrated infrared emitter for use in the drying or heattreatment of webs, so as to maximize the utilization of infrared energyto heat and/or dry the web when in combination with at least onesecondary air jet. The at least one secondary air jet is supplied byabout 5 to 40% of the total air (preferably 7 to 15%) which is firstheated by passing in fluid contact with at least one infrared emitterand is preferably also guided in fluid contact with a reflector, andfurther guided in fluid contact with a lens that is transmissible toinfrared energy. The secondary jet is guided in fluid contact in asubstantially parallel flow direction to the lens surfaces and providesat least a portion of the flotation air in conjunction with the at leastone primary air jet, the parallel flow providing sufficient cooling tothe emitter, reflector and lens elements to prevent ignition ofcombustible web or coating materials even under upset conditions. Anoptimum amount of cooling air is guided in contact with the emitter,reflector and lens surfaces to promote effective cooling of the emitter,reflector and lens, and further the cooling air is guided aftercontacting and gaining heat from said surfaces to deliver mass flow andthermal energy to the web by convection. The cooling air is also guidedover the surfaces to prevent contact of the solvent-laden air inside thedrying enclosure from contacting said surfaces, thus preventing theircontamination.

From the forgoing discussion, it can be appreciated that the combinedconvection and radiation heat transfer modes of the present inventionare driven substantially independently by virtue of the convection airtemperature and emitter temperature, respectively. This feature can beused to advantage in the embodiments disclosed herein for the purpose ofrapidly drying high moisture areas without excessively heating lowmoisture areas. Such disparities in moisture across a web are common inprinting where heavy ink images are present alongside of low coverage orunprinted areas. The embodiments disclosed herein provide a selectivityin heating wet areas in that the heavy print areas require large heatflux to dry quickly and remain at or near the wet bulb temperature dueto the evaporative cooling effect, thus these areas will besubstantially heated by both the radiation and the high velocityconvection modes provided by this infrared floatation air bar. On theother hand, those areas having little or no coverage will tend toincrease in temperature by the infrared radiation from the emitters, butnear the exit of the dryer can be cooled by the convection air to avoidoverheating. The electromagnetic energy from the infrared elements isemitted at a relatively high temperature (typically >2000° F.) comparedto the web temperature (typically 150 to 300° F.). As a result,according to the Stefan-Boltzman law the emissive heat flux to the webchanges relatively little as the web temperature increases because theemitter temperature is quite high and the emitter temperature dominatesthe radiation flux potential according to the forth power of absolutetemperature. By contrast, the heat transfer by convection is driven by alinear potential between air temperature and web temperature. Themaximum web temperature for a given web material being thermallyprocessed is often limited during the drying operation in order to avoidquality defects in the web or coating. When ink or coating materials areoverheated beyond their maximum thermal rating as specified by themanufacturer, they may degrade in function and appearance often becomingdiscolored, brittle or chalky. Similarly, if the web substrate materialsare overheated beyond their maximum thermal rating as specified by themanufacturer they may degrade in mechanical performance as well asappearance, often becoming discolored, brittle or distorted. Forexample, polymer web materials such as PET may soften and stretchcausing distortion of the initially planar web resulting in waves orcockling, especially at temperatures exceeding 200° F. Paper webs mayexhibit similar out-of-plane distortion due to hygroscopic shrinkage ofover-dried areas having less than 3% moisture in proximity to heavycoated or printed areas having moisture levels several percent higherthan the adjoining areas. Paperboard tends to curl if the moisture onone side is reduced to levels several percent lower than the oppositeside. Additionally, paper and paperboard material will tend to brown andbecome brittle at temperatures in the range of 350 to 400° F., andeventually burn at higher temperatures. In order to avoid theseproblems, printers and converters of web materials will be familiar withthe maximum temperature limitations for processing of the web andcoating through specifications provided by the suppliers of thematerials, or from pilot drying trials, or by experience with same orsimilar materials in prior production processing. In embodimentsdisclosed herein, if the air temperature set point is selected at atemperature just below the maximum web temperature to be tolerated inthe hottest (driest) areas of the web, the infrared heating in theseareas will be countered by convective cooling, thus mitigating excessivetemperature in said driest areas. Air temperature set points from 10 to50 Fahrenheit degrees below the maximum web temperature to be toleratedwere found to be effective in avoiding overheating of the web.Alternatively, the air temperature may be selected and regulated to betypically in the range of 30 to 100 Fahrenheit degrees above the wetbulb temperature in the dryer (wet bulb typically <180° F.) theconvective flux potential is diminished and even reversed, thus slowingthe rate of heating of the web in the driest areas once the webtemperature in those areas exceeds the air temperature.

In order to limit the overheating of the driest areas as described, theconvection coefficient provided by the infrared air bars must besuitably high, exceeding that of conventional cooling air systemsemployed in non-flotation infrared dryers. Suitable air bar heatconvection heat transfer coefficients are in the range of about 10 toabout 40 BTU/hr-ft²-F. Suitable air bar slot jet velocities are in therange of from about 5000 to about 16000 feet per minute.

The air temperature supplied to the nozzles may be regulated by adding acontrolled input of heat from an independent heat source such as anelectric resistance coil, hot oil or steam coil, or a burner located inthe ducting supplying the air to bars. In preferred embodiments, theneed for an independent source of heat is obviated by recovering theheat from the emitters that is not absorbed by the radiation mode intothe web into the re-circulated air. This includes the heat taken up inthe emitter cooling air as previously described, and similarly the heatrecovered from stray infrared energy (electromagnetic waves that reflector otherwise impinge on surfaces other than the web) that tends toelevate the temperature of other surfaces inside the dryer over whichthe re-circulation air flows, and heat from those areas of the web thathave been heated above the supply air temperature by the radiation modeas described earlier. This heat recovered in the re-circulation air maybe retained by minimizing the amount of air exhausted to about 10% orless of the air bar supply air thus maximizing the re-circulating airtemperature. On the other hand, if it is desired to lower the airtemperature, the amount of exhaust may be increased to about 30% or morethus drawing in more ambient air that must be heated in there-circulating flow. Those skilled in the art of dryers will be familiarwith regulation of exhaust flow by means of a damper, or fan with avariable speed drive, in order to accomplish the air flow regulationdescribed. This regulation may be done manually by an operator or by aclosed-loop controller sensing air temperature and modulating theexhaust flow accordingly. In another preferred embodiment, the airtemperature may be regulated by modulating the input power to at leastone infrared emitter through a closed-loop controller. In the mostpreferred embodiment, the primary regulation of the air temperature ismade by setting the dryer exhaust to achieve a desired temperature aspreviously mentioned, and further controlled by regulating the power toat least one emitter with a closed-loop controller which regulates theset point for the power output of an SCR supplying power to the at leastone emitter.

In one application example, a printed paper web with a water-based ink,is to be dried. The expected wet bulb temperature is 135° F. and theconvection air temperature is set to 170° F. The net radiative heat fluxfrom the emitters to the unprinted web is 6,500 BTU/hr-ft² and theconvection coefficient per side is 25 BTU/hr-ft²-F. Thus the initialcombined convection and radiation heating rate is 11,500 BTU/hr-ft² andthe terminal temperature of the web, where radiation flux is offset byconvection cooling in the unprinted areas of the web, will be ˜300° F.Without the contributing effects of the flotation air bar convectionair, the initial heating rate is only 6,500 BTU/hr-ft² resulting inslower heating, and the calculated terminal temperature is over 800° F.,well above the ignition point of paper.

In the preferred dryer embodiment, the infrared air bars are placed 8 to20 inches apart on each side of the web, with nozzle air jet velocitiesin the range of 5000 to 16,000 fpm, with the total emitter heat flux peremitter element mounted in each air bar in the range of 100 to 200 wattsper inch for medium wave carbon emitters, and 200 to 400 watts per inchfor near IR emitters. Air temperature set points in the range of 150 to250° F. are preferred for water based coatings on paper substrates.

What is claimed is:
 1. An air flotation bar, comprising: a header, firstand second primary discharge slots for discharging fluid for supportinga web; a channel assembly positioned between said first and secondprimary discharge slots and comprising an internal compartmentcontaining: an infrared light source for emitting electromagneticenergy, a reflector for reflecting electromagnetic energy emitted bysaid infrared light source, and a lens having a web-facing surface; atleast one aperture in said channel assembly for introducing fluid intosaid internal compartment for cooling said infrared light source andsaid reflector; and at least one secondary discharge slot configured todischarge said fluid introduced into said internal compartment parallelto said web-facing surface of said lens and to said web; wherein saidfirst and second primary discharge slots and said at least one secondarydischarge slot are configured such that 5% to 40% of total air isdischarged via said at least one secondary discharge slot.
 2. The airflotation bar of claim 1, wherein said channel is removable from saidbar.
 3. The air flotation bar of claim 1, wherein said first primarydischarge slot is a Coanda slot.
 4. The air flotation bar of claim 1,wherein said second primary discharge slot is downstream, in thedirection of web travel, of said first primary discharge slot.
 5. Theair flotation bar of claim 1, wherein said lens is transmissive toinfrared light emitted from said infrared light source.
 6. The airflotation bar of claim 5, wherein said infrared light source radiatesdirectly through said lens to transmit infrared energy to a traversingweb.
 7. The air flotation bar of claim 5, wherein said infrared lightsource radiates infrared energy that reflects off said reflector andthrough said lens to impart infrared energy to a traversing web.
 8. Theair flotation bar of claim 1, wherein the open area of said at least oneaperture is adjustable.
 9. The air flotation bar of claim 8, furthercomprising an adjustment member having at least one adjustment aperture,said member being slidable with respect to said channel to adjust therelative position of said at least one adjustment aperture and saidaperture in said channel to adjust the open area of said aperture insaid channel.
 10. The air flotation bar of claim 1, wherein said firstand second primary discharge air slots and said at least one secondarydischarge air slot are configured such that 7% to 15% of total air isdischarged via said at least one secondary discharge slot.
 11. A webdryer comprising a housing containing a plurality of air flotation bars;wherein the air flotation bar comprises: a header, first and secondprimary discharge slots for discharging fluid for supporting a web; achannel assembly positioned between said first and second primarydischarge slots and comprising an internal compartment containing: aninfrared light source for emitting electromagnetic energy, a reflectorfor reflecting electromagnetic energy emitted by said infrared lightsource, and a lens having a web-facing surface; at least one aperture insaid channel assembly for introducing fluid into said internalcompartment for cooling said infrared light source and said reflector;and at least one secondary discharge slot configured to discharge saidfluid introduced into said internal compartment parallel to saidweb-facing surface of said lens and to said web; wherein said first andsecond primary discharge slots and said at least one secondary dischargeslot are configured such that 5% to 40% of total air is discharged viasaid at least one secondary discharge slot.